Connect sill repair part 1, 2 , 3 showing before repair

[metalworker0]

First two videos showing extent of rust before i then replace sill and make repairs to inner and outer sill on my 2006 transit connect

1. showing extent of rust, also quick peak at some of the work that has been finished on the drivers side - note the bulge and crushing where its been jacked up on the slopped area and its slightly pushed up towards the door.

https://www.youtube.com/watch?v=hweO04SLiGA

2 . showing swollen bottom of sill where; inner, middle and outer come together

https://www.youtube.com/watch?v=_DmCarFJvt4

video 3 in a day or to, after i cut it open to show the innards.....there are quite a few botched repairs and rear end is heavily disguised by the looks of things

before that i will pressure wash and de-grease the underside .......so it's all able to take paint later...like to get all the wet and dirty jobs done first.

all the best.mark

[metalworker0]

stand2.jpg

Positioning of axle stands ...note the screw jack at the front is to take the weight of the engine , stop the van flexing when i take the rusty sill away.

There are 4 axle stands and 1 screw jack in place.

the proper way is to take the door off and weld a strut across the door gap that would be on a car ........but there is enough strength in the chassis members, they are quite thick and carry most or all the weight ..the sill sections are very thin and don't contribute that much.

The van is lifted up about 22 inches (measured from mid way along bottom of sill) ..the maximum i could lift it ..as i struggled with room when i did the other side ...
Note: Don't lift it any more than that, as i reckon 26 inches is the tipping point

[metalworker0]

ok away we go .
first cut along top of sill slightly below of the indents that are arrow symbols, and cut down the sides...this is an investigative opening that you can enlarge to full extent of what you want to replace later.



fold horizontally ,so that when you cut along the bottom you can see where the cutting disk is going.

[metalworker0]

showing botched patches on the removed section....second picture is first picture is inside

[metalworker0]

more patches outside and what you see inside

[metalworker0]

the sill removed

[metalworker0]

the sill removed

[metalworker0]

showing distortion to the door step , where it had been jacked up in the wrong place in the past

[metalworker0]

BAD - showing full extent of the rust ...innner middle and outer need woerk ......a long job me thinks, going to take a while

[metalworker0]

Video
https://www.youtube.com/watch?v=UkC9JswOSPU

feel free to comment now ..as the rest of the work will take a while

[metalworker0]

well remember me mentioning the strengthener brace welded across the door ..to keep it from sagging whilst you replace the panels ..
Now because I've got to remove so much metal behind those upper chassis members .the middle sill is the closing section of those upper members

i will have to weld a temporary angle iron to the front of the chassis member .....will act just the same as the door brace.

cant use door brace as its outside and taking the door off is not on the books .

have to ride bicycle 6 miles to nearest fabricator to get angle iron, some how get it back here 5 foot

[Altransit]

You have yourself quite a task there

I've not done anything like this since I owned an Austin 1300 back in the seventies, then it was gas welding, and I managed to set fire to the carpets

Whereabouts in the country are you There may be another local member able to help out with transport

[metalworker0]

I'm in prestatyn North wales ..i got the stuff from the fabricator today, brought home 25mm x 25mm box section ./..should have brought home angle iron ..i thought the box would be better, don't think it will be!
kind of hard pedaling home with a 7 foot box section .

Anyway steel is a hell of a price now

7 foot .........i said how much .....he said £15.......i said whatttttttt, he said how much were you expecting ..i said a fiver
i ended u paying a tenner

Looked when i got home on ebay ..if i had bought a 7 foot piece off ebay, it would have been over £20, so he wasn't telling porkies

[Altransit]

Oh, that's a bit far for me to help you out, although my son is probably driving past you right now on the A55 bound for Holyhead (not much help, I know )


Keep up the good work, it's interesting to see

[metalworker0]

The steel bought was no good, very hard to get something that fits in there and be able to weld the top of it...so found two old angle irons in my workshop and welded them together ..these are the best fit possible and are 1" x1" they are not that, rusty its bit of paint and dirt..cam makes them look rusty

so strengthening brace added (needed before more metal is removed)..........i may leave it in there permanently..